Technofriendz A community of technical scholars HARDWAR TRAINING REPORT. Project Report By Rajeev Prajapati

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1 HARDWAR TRAINING REPORT SUBMITTED TO : GENERAL MANAGER CFFP (BHEL) SUBMITTED BY: RAJEEV KUMAR ELECTRICAL ENGG.

2 COLLEGE OF ENGINEERING ROORKEE ACKNOWLEDGEMENT An Engineering Diploma is incomplete without practical knowledge and skills. An engineer is expected to be a designer of dynamic world of innovation for which practical experience matters a lot It gives me a great pleasure to have an opportunity to acknowledge and to express gratitude to those who were associated with my project training in BHEL, HARIDWAR. Special thanks to GENERAL MANAGER CFFP, BHEL for his Incessant support. And guidance throughout my project training. I am grateful to MR. KHUSHWANT SINGH (VPI) for his support. I express my sincere thanks and gratitude to BHEL authorities for allowing me to undergo my project training in this Prestigious Organization. I shall always remain Indebted to them their constant interest and excellent guidance in my Project work. I acknowledge to the support of other authorities also with a deep sense of gratitude.

3 SAFETY S - Science for Self & Society A - Art of Action for Accidence Avoidance F - Foolproof with failsafe devices E - Engineering control to system T - Training & Teaching to all Y - Yardstick to save humanity Factor Impending the Safety: Personal Factors III health, Age, Physical disability Physiological Factors Work environmental factors / problems, Rest pause cycle. Psychological Factors Worries, depression, aggression. Sociological Factors (a) Safety literature in regional language, tendency for bargaining for unsafe & unhealthy working conditions. (b) Lack of interest in the job/employment. Job Climate & its Defects on attitude Job training, Incomplete/untrained supervisory personal, Poor working conditions, Political interference. Unsafe Act Abuse of safety devises. Unsafe working procedure. Moving near running part of the machines. Horseplay, Use of drug, quarrelling. Lack of personal protective equipment. Lack of attention. Unsafe Conditions Inadequate machine guarding.

4 Defective tools Unsafe design/construction of the work place. Improper illumination. Excess Noise Poor housing keeping Excess heat in work place Safety is the responsibility of every one One has not only to provide Safe & Best product but also create a climate where the safe operation can be possible. The safety means, not only to prevent the accident but also Control of occupational health To make machine or equipment or situation totally safe. Taking in mind for safe operation activities for man, machine, material & money.

5 BHEL is the largest engineering and manufacturing enterprise in India in the energy-related / infrastructure sector, today. BHEL was established more than 40 years ago, ushering in the indigenous Heavy Electrical Equipment industry in India a dream that has been more than realized with a well recognized track record of performance. The company has been earning profits continuously since and paying dividends since BHEL caters to core sectors of the Indian Economy viz., Power Generation & transmission, Industry, Transportation, Telecommunication, Renewable Energy and Defense etc. The wide network of BHEL's 14 manufacturing division, four power sectors regional centers, over 100 project sites, eight service center and 14 regional offices enables the company to be closer to its customers and provide them with suitable products, systems and services efficiently and at competitive prices. Having attained ISO9000,ISO14000,ISO18000 certification, BHEL is now well on its journey towards Total Quality Management (TQM). BHEL has Installed equipment for over 90,000 MW of power generation for utilities, captive and Industrial users. Supplied over MVA transformer capacity and other equipment operating in Transmission and Distribution network upto 400 KV (AC & DC). Supplied over Motors with drive control system to power projects, petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants, etc. Supplied Traction electrics and AC / DC locos to power over Kms Railway network.

6 Technofriendz Supplied over one million valves to power plants and other Industries organization BHEL, Haridwar a) Vision:- A world class Engineering Enterprise committed to Enhancing stakeholder value. b) Mission:- To be an Indian Multinational Engineering Enterprise providing total Business solutions through quality products, systems and services in the fields of Energy, Industry, Transportation. Infrastructure and other potential areas. c) VALUES:- Meeting commitments made to external & internal customers. Foster learing,creativity and speed of response. Respect for dignity and potential of individuals. Loyality and pride in the company. Team playing. Zeal to excel. Integrity and fairness in all matters. BHEL, Haridwar Complex a) Area:- BHEL, Haridwar complex consist of two manufacturing units, namely Heavy Electrical Equipment Plant (HEEP) and central Foundry, Forge Plant (CFFP). The approximate area of these plant is a follows: HEEP: CFFP: b) Location: sq km. (Approx.) 1.0 sq km. (Approx.) BHEL, Haridwar complex is situated in the foot hills of Shivalik range in Haridwar district of Uttaranchal state. The main Administrative Building is a distance of about 6 km from Haridwar Railway station.

7 Product Profile HEEP S.No. Products 1 Thermal Sets 3000 MW 2 Hydro Sets 625 MW 3 Electric Machines 450 MW Installed capacity (Licensed) 4 Gas to 600 MW 5 Super Rapid gun 3 Nos. Capacity installed for manufacturing of gas turbines like rotor equivalent to 600 MW Gas turbines. Balance components for gas turbines from existing thermal sets facilities. CFFP S.No. Products Installed capacity (Licensed) 1 Castings 6000 MT 2 Forgings a. Heavy forgings b. Medium forgings 2410 MT 3000 MT 3 Billets and Blooms 4000 MT 4 CI castings 7180 MT 5 Non ferrous castings 250 MT Facilities in HEEP S.No. Area / Block Major Facilities Products 1. Block-I Machine shop, winding bar Turbo generators, (Electrical Machines preparation, assembling, painting section, packing and preservation, exciters, Motors (AC & DC).

8 2. Block-II (Fabrication Block) oven speed balancing, test bed, test stand, micalastic impregnation, babbitting etc. Marking, cutting, straightening, gas cutting, press, welding grinding, assembly, heat treatment, cleaning and shot blasting, machining, fabrication of pipe coolers, painting. Large size fabricated assembles/ components for power equipments 3. Block-III (Turbine and Auxiliary block) 4. Block-IV (Feeder block) Machining, assembly, preservation and packing, test stands/ station, painting, grinding, broaching, facing, wax metting, milling, polishing etc. Bar winding, mechanical assembly, armature windings, sheet metal working, machining, copper profile drawing, electroplating, impregnation, machining and preparation of insulating components plastic moulding, press moulding. Steam turbines, hydro turbines, gas turbines, turbine blades, special tooling. Windings for turbo generators, hydro generators, insulation for AC and DC motors, insulating components for TG, HG and Motors, control panels, contact relays, master control etc. 5. Block-V Fabrication, pneumatic hammer for forging, gas fired furnaces, hydraulic manipulators. Fabricated parts of steam turbine water box, storage tank, hydro assemblies components. turbines and 6. Block-VI (Fibrication) Welding, drilling shot blasting, CNC flame cutting, CNC deep drilling, shot blasting, sheet metal work, assembly. Fabricated oil tanks, hollow guide blades, rings, stator frames,

9 7. Block-VI (Stamping and Dia manufacturing) Machining, turning, grinding, jig boring, stamping press, de-varnishing, de-greasing, de-rusting, varnishing, spot welding, painting. rotor spiders. All types of dies, including stamping dies and press forms stamping for generators & motors. BHEL:- Technology / Collaborations:- The technology base of BHEL in the area of steam turbines and Turbo generators has been created by acquiring technological information from the collaborators. Initially BHEL had collaboration with M/s LMW USSR for 100 and 210 MW sets. In 1976, BHEL interred into technical collaboration agreement with M/s Siemens Kwu, Germany to acquire the know-how and know-why for turbine generator sets upto 1000 MW. This collaboration still continues. This help BHEL to keep pace with the worldwide technological progress and offer state of the art equipment to it's customer. Under this collaboration agreement BHEL has established strong design manufacturing and servicing base for units upto 500 MW ratings. Manufacturing Facilities:- HEEP Haridwar plant is equipped with most modern and sophisticated machines tools, facilities and test equipment to manufacture and test generators upto 1000 MW rating, which include. 1) Most modern micalastic insulation plant for stator bars. 2) Over speed and vacuum balancing tunnel. 3) Kollmann rotor slot milling machine upto maximum barrel length of 7000 mm, barrel diameter of 1800 mm and rotor weight of 225 tones. 4) Two computerized test beds to test large size generators upto 1000 MW.

10 5) Wotan CNC horizontal boring maching. 6) Center lathe machine upto maximum length of 16 m and diameter of 3.15 m. 7) Insulation life endurance test assessment facility. Beside these, HEEP has also set up a Generator Research Institute with an objective to develop basis know-how and know-why through experimental studies for reliable, efficient and optimum design of generators and improve their performance in service. (A) Turbo Generator Main Components 1. Stator: (a) Stator Frame (b) End Shields (c) Bushing Compartment. The stator frame with flexible core suspension components, core, and stator winding is the heaviest component of the entire generator. A rigid frame is required due to forces and torques arising during operation. In addition, the use of hydrogen for the generator cooling requires the frame to be pressure resistant upto an internal pressure of approx 10 bar. The welding stator frame consist of the cylindrical frame housing two flanged rings and axial and radial ribs. Housing and ribs within the range of the phase connectors of the stator winding are made of non magnetic steel to prevent eddy current losses, while the remaining frame parts are fabricated from structural steel. The arrangement and dimensioning of the ribs are determined by the cooling gas passages and the required mechanical strength and stiffness. Dimensioning is also dictated by vibrational considerations, resulting partly in greater wall thickness than required from the point of view of mechanical strength. The natural frequency of frame does not correspond to any exciting frequencies.

11 Two lateral support for flexible core suspension in the frame are located directly adjacent to the points where the frame is supported on the foundation. Due to the rigid design of the supports and foot portion the forces due to weight and short-circuits will not result in any over-stressing of the frame. Manifolds are arranged inside the stator frame at the bottom and top for filling the generator with CO 2 and H 2. The connection of the manifolds are located side by side in the lower part of the frame housing. Additional opening in the housing, which are sealed gas tight by pressure resistant covers, afford access to the core clamping flanges of the flexible core suspension system and permit the lower portion of the core to be inspected Access to the end winding compartments is possible through manholes in the end shield. In the lower part of the frame at the exciter end an opening is provided for bringing out the winding ends. The generator terminal box is flanged to this opening. The ends of the stator frame are closed by pressure contaning end shields. The End Shield features a high stiffness and accommodate the generator bearings, shaft seals and hydrogen coolers. The end shields are horizontally split to allow for assembly. The end shields contains the generator bearings. This result in a minimum distance between bearings and permits the overall axial length of the TE end shield to be utilized for accommodation of the hydrogen cooler sections. Cooler wells are provided on the end shield on both sides of the bearing compartment for this purpose one man hole in both the upper and lower half of end shield provides access to the end winding compartments of the completely assembled machine. Inside the bearing compartment the bearing saddle is mounted and insulated from the lower half end shields. The bearing saddle supports the spherical bearing sleeve and insulates it from ground to prevent the flow of shaft currents. The bearing oil is supplied to the bearing saddle via a pipe permanently installed in the end shield and is then passed on to the lubricating gap through

12 ducts in the lower bearing sleeve. The bearing drain oil is collected in the bearing compartment and discharged the lower half of the end shield via a pipe. The bearing compartment is sealed on the air side with labyrinth rings. On the hydrogen side the bearing compartment is closed by the shaft seal and labyrinth rings. The oil for the shaft seal is admitted via integrally welded pipes. The seal oil drained toward the air side is drained together with the bearing oil. The seal oil drained towards the hydrogen side is first collected in a gas and oil tight chamber below the bearing compartment for deforming and then passed via a siphon to the seal oil tank of the hydrogen side seal oil circuit. The static and dynamic bearing forces are directly transmitted to the foundation via lateral feet attached to the lower half end shield. The feet can be detached from the end shield, since the end shields must be lowered into the foundation opening for rotor insertion. Stator Frame: The stator frame consist of a cylindrical center section and two end shields which are gas tight and pressure resistant. The stator end shields are joined and sealed to the stator frame with an O- ring and bolted flange connection the stator frame accomdates the electrically active part of the stator, i.e. the stator core and the stator windings. Both the gas ducts and a large number of welded circular ribs provides for the rigidity of the stator frame. Ring shaped support for resilient core suspension are arranged between the circular ribs. The generator cooler is subdivided into cooler sections arranged vertically in the turbine side stator End Shield. Stator End Shield also contain the shaft seal and bearing components. Feet are welded to the stator frame and end shields to support the stator on the foundation. The Stator is firmly connected to foundation with anchor bolts through the feet.

13 Stator Core: The stator core is stacked from insulated electrical sheet-steel laminations and mounted in supporting rings over insulated dovetail guide bars. Axial compression of the stator core is obtained by clamping fingers, pressure plates and non-magnetic through type clamping bolts, which are insulated from the core. The supporting rings form part of an inner frame cage. This cage is suspended in the outer frame by a large number of separate flat springs distributed over the entire core length. The flat springs are tangentially arranged on the circumference in sets with three springs each i.e. two vertical supporting ring on both sides of the core and one horizontal stabilizing ring below the core. The springs are so arranged and tuned that forced vibrations of the core resulting from the magnetic field will not be transmitted to the frame and foundation. The pressure plates and end portion of the stator core are effectively shielded against stray magnetic fields. The flux shields are cooled by a flow of hydrogen gas directly over the assembly. Stator Winding: 1. Construction:- Stator bars, phase connectors and bushings are designed for direct water cooling. To minimize the stray losses, the bars are composed of separately insulated strands which are transposed by 540 in the slot portion and bonded together with epoxy resin in heated mold after bending the end turns are likewise bonded together with baked synthetic resin filters. The bar consist of solid and hollow strands distributed over the entire bar cross-section so that good heat dissipation is ensured at the bar ends, all the solid strand are jointly brazed into a connection sleeve and the hollow strands into a water box from which the cooling water enters and exits via Teflon insulating hoses connected to the annular manifolds. The electrical connection between top and bottom bars is made by a bolted connection at the connection sleeve.

14 The water manifolds are insulated from stator frame, permitting the insulation resistance of water-filled winding to be measured. During operation water manifolds are grounded. 2. Micalastic High Voltage Insulation: High-voltage insulation is provided according to the proven Micalastic system. With this insulation system, several half over lapped continuous layer of mica tape are applied to the bars. The mica tape is built up from large area mica splitting which are sandwiched between two polyester backed fabric layers with epoxy as an adhesive. The number of layers, i.e., the thickness of the insulation depends on the machine voltage. The bars are dried under vacuum and impregnated with epoxy resin which has very good penetration properties due to its low viscosity. After impregnation under vacuum, the bars are subjected to pressure, with nitrogen being used as pressurizing medium (VPI process). The impregnation bars are formed to the required shape in molds and cured in an over at high temperature. The highvoltage insulation obtained is nearly void-free and is characterized by its excellent electrical, mechanical and thermal properties in addition to being fully waterproof and oil resistant. To minimize corona discharges between the insulation and slot wall, a final coat of semi conducting varnish is applied to the surfaces of all bars within the slot range. In addition, all bars are provided with an end corona protection, to control the electric field at the transition from the slot to the end winding and to prevent the formation of creep age spark concentrations. Bar Support System:- To protect the stator winding against the effects of magnetic forces due to load and to ensure permanent firm seating of the bars in the slots during operation, the bars are inserted with a side ripple spring, a slot bottom equalizing strip, and a top ripple spring located beneath the slot wedge. The gaps between the bars in the stator end windings are completely filled with insulating material and cured after

15 installation. For radial support the end windings are clamped to a rigid support ring of insulating material which in then is fully supported by the frame. Hot curing conforming fillers arranged between the stator bars and the support ring ensures a firm support of each individual bar against the support ring. The bars are clamped to the support ring with pressure plates held by clamping bolts made from a high strength insulating material. The support ring is free to move axially within the stator frame so that movements of the winding due to thermal expansion are not restricted. The stator winding connections are brought out to six bushings located in a compartment of welded non-magnetic steel below the generator at the exciter end. Current transformer for metering and relaying purposes can be mounted on the bushings. Total Impregnation facility in BHEL:- Facilities:- 1. Impregnation capacity upto turbo generators of 470 MVA. 2. Main Impregnation tank. height = 4.5 meters and length = 9 meters. 3. Resin tank 5 number of tank with a storage capacity = litres per tank. 4. Total resin storage capacity = 60,000 litres. 5. Explosive proof software controlled oven with rotor facility. VPI Process:- 1. Assembly of winding bars in green stage and impregnation of assembled wound core.

16 2. Pre heating and curing oven for about 1hour. 3. Drying under vacuum (< = 0.1 m bar) 4. Impregnation with resin mix and pressure is increased gradually to ensure filling of voids. 5. Curing in oven at 145 o C for minimum 8 hours. 6. Epoxy resin fills all gaps / voids by capillary action without blocking vent canals due to its low viscosity. Process Before:- Stator bar Stator bar Stator bar forming Insulation Impregnation Number of parallel activities = 2 Stator Stator Stator Winding frame Core and fabrication assembly assembly Process After: Stator bar Core Assembly Stator frame fabrication Advantages: 1. Rotor withdrawal during initial inspection not required. forming Number of parallel activities = 3 stator Stator frame machine 2. Possibility of loosening of core and fasteness eliminated. Stator 3. bar Big insulation saving in spares Impregnation cost. of wound core Stator Assembly 4. Reduction in time as above by 5-6 days. 5. Additional revenue of approx Rs 3750 lakhs. 6. Improved heat transfer during operation. 7. Manufacturing cycle time reduction by 4-5 months. 8. Void free high voltage Insulation. 9. Mechanically firm winding between core and winding component better suited against thermal stress. 10. Thermal conductivity of VPI insulation = mw / cm - o C against that of air = mw / cm o C.

17 Hydraulic Testing and Anchoring of stator frame:- 1.Hydraulic Testing of Stator Frame: The empty stator frame with attached end shields and terminal box is subjected to a hydraulic test at 10 bar to ensure that it will be capable of with standing maximum explosion pressures. The water pressure is increased in steps, with the pressure being reduced to atmospheric pressure after each step to allow for measurement of any permanent deformations. This test also check for leakage at the weld seams. In addition the welded structure is subjected to an air pressure test to check its gastightness. 2. Sealing the bolted flange joints: The bolted flange joints which must be gastight (e.g., end shields, terminal box, manhole covers) are sealed with elastically deformed O-ring packings. Each O-ring packing is inserted into a large groove of rectangular cross-section and compressed by the flanges. The elastic deformation of the O-ring packing provides for a sufficient sealing force. 3. Anchoring and Aligning the stator frame and End Shields to the foundation: The stator frame is anchored to the foundation with anchor bolts in conjunction with aligning elements and sole plates set in grout on the foundation. The leveling screws are screwed into the support fort of the frame and permit a rapid and exact alignment of the stator. To ensure a uniform transmission of the forces they are arranged symmetrically about the anchor bolts. The spherical portion of the leveling screws ensures complete contact and thus a rigid connection between stator and foundation. The stator end shields are aligned on the machine sole plates with shims.

18 Different thermal expansion of the stator and foundation result in differential movements between the frame and machine sole plates. The stator is therefore fixed in position in a manner allowing for expansion while retaining alignment. Fixed keys located at the feet in the middle of the stator frame secure the frame axially in a central position. In order to minimize the hysterics and eddy current losses of the rotating magnetic flux which interacts with the core, the entire core is build up of thin laminations Each lamination layer is made up from a number of individual segments. The segments are punched in one operation from 0.5 mm thick electrical sheet-steel laminations having a high silicon content, carefully deburred and then coated with insulating varnish on both the sides. The stator frame is turned on end while the core is stacked with lamination segments in individual layers. The segments are staggered from layer to layer so that a core of high mechanical strength and uniform permeability to magnetic flux is obtained. On the outer circumference the segments are stacked on insulated dovetail bars, which hold them in position. One dovetail bar is not insulated to provide for grounding of the laminated core, stacking guides are inserted into the winding slot during stacking provide smooth slot walls. To obtain the maximum compression and eliminate under scathing during operation, the laminations are hydraulically compressed and heated during the stacking procedure when certain heights of stacks are reached the complete stack is kept under pressure and located in a frame by means of clamping bolts and pressure plates. The clamping bolts running through the core are made of non magnetic steel and are insulated from the core and the pressure plates to prevent the clamping bolts from short-circuiting the laminations and allowing the flow of eddy currents. The pressure is transmitted from the pressure plates to the core by clamping fingers. The clamping finger extends upto the end of the teeth, thus ensuring a firm

19 compression in the area of the teeth. The stepped arrangement of the laminations at the core ends provides for an efficient support of the tooth portion and, in addition contributes to a reduction of eddy current losses and local heating in this area. The clamping fingers are made of non-magnetic steel to avoid eddy current losses. For protection against the effect of stray flux in the coil ends, the pressure plate and core end portion are shielded by gas-cooled rings of insulation bonded electrical sheet-steal. To remove the heat, spacer segments, placed at intervals along the bore length, divide the core into sections to provide radial passages for cooling gas flow. In the core end portions the cooling ducts are winder and spaced more closely to account for the higher losses and to ensure more intensive cooling of the narrow core sections. Spring Support of Stator Core:- The revolving magnetic field exerts a pull on the core, resulting in a revolving and nearly elliptical deformation of the core which sets up a stator vibration at twice the system frequency. To reduce the transmission of these dynamic vibrations to the foundation, the generator core is spring mounted in the stator frame. The core is supported in several sets of rings. Each ring set consists of two supporting rings and two core clamping rings. The structural members to which the insulated dovetail bars are bolted are uniformly positioned around the supporting ring interior to support the core and to take up the torque acting on the core. For firm coupling of the ring sets to the core, the supporting ring is solidly pressed against the core by the clamping ring. The clamping ring consist of two parts which are held together by two clamps. Tightening the clamps reduces the gap between the ring segments so that the supporting ring is pressed firmly against the core. Each ring set is linked to the frame by three flat springs. The core is supported in the frame via two vertical springs in the vicinity of the generator feet.

20 The lower springs prevents a lateral deflection of the core. The flat springs are resilient to radial movements of the core suspension points and will largely resist transmission of double frequency vibration to the frame. In the tangential direction they are, however sufficiently rigid to take up the short circuit torque of the unit. The entire vibration system is turned so as to avoid resonance with vibrations at system frequency or twice the system frequency. Locating the Bars:- The stator windings are placed in rectangular slots which are uniformly distributed around the circumference of the stator core. The bars are protected by a cemented graphitized paper wrapped over the slot portion of the bar. The bars fit tightly in the slots. Manufacturing tolerance are compensated with semi-conducting filler strips along the bar sides which ensure good contact between the outer corona protection and the slot wall. Radial slot positioning of the bar is done with slot wedges. Below the longitudinally divided slot wedges a top ripple spring of high-strength fiber glass fabric is arranged between the filler and slide strip which presses the bar against the slot bottom with a specific preloading. An equalizing strip is inserted at the slot bottom to compensate any unevenness in the bar shape and slot bottom surface during bar insertion. The strip is cured after insertions of the bars. These measures prevent vibrations. The specific preloading is checked at each slot wedge. With the windings placed in the slots, the bar ends form a cone-shaped end winding. A small cone taper is used to keep the stray losses at a minimum. Any gaps in the end winding due to design or manufacturing are filled with curable plastic fillers, ensuring solid support of the cone-shaped top and bottom layers. The two bar layers are braced with clamping bolts of high-strength fiber glass fabric against a rigid, tapered supporting ring of insulating material. Tight seating is ensured by plastic filler on both sides of the bars which are cured on completion of winding assembly.

21 Each end winding thus forms a compact, self supporting arch of high rigidity which prevents bar vibration during operation and can with stand short circuit forces. In addition, the end turn covering provides good protection against external damage. The supporting rings rest on supporting brackets which are capable of moving in the axial direction. This allow for a differential movement between the end windings and the core as a result of different thermal expansions. Electrical connection of bars:- The electrical connection of top and bottom bars is by a bolted contact surface. At their ends the strands are brazed into a connecting sleeve, the strand rows being separated from each other by spacers. The contact surfaces of the connecting sleeves for the top and bottom bars are pressed against each other by nonmagnetic clamping bolts. Special care is taken to obtain flat and parallel contact surfaces. In order to prevent any reduction in contact pressure or any plastic deformations due to excessive contact pressure, Belleville washers are arranged on the clamping bolts which ensure a uniform and constant contact pressure. Water Supply:- The water connection at the stator bar is separate from the electrical connection. As a result no electrical forces can act on the water connection. Which the solid strands of the stator bars terminates at the connecting sleeve, the hollow strands are beared into water boxes, with solid spacers inserted to compensate for the solid strand. Each water box is consist of two part i.e., the sleeve shaped lower part enclosing the hollow strands and the cover type upper part the strand rows are separated from each other by spacers. Each water box is provided with a pipe connection of non magnetic stainless steel for connection of the hose. The exciter end water boxes serve for water admission and distribute the cooling water uniformly to the hollow strand of the bars. The hot water is collected

22 on leaving the hollow strand in the turbine end water boxes. The cooling water is then discharged from the generator via the hoses and the ring header. During manufacturing of the stator bars, various checks are performed to ensure water tightness and unobstructed water passages. The flow check ensures that no reduction in the cross-sectional area of the strand ducts has occurred, and that all strands are passed by identical water flows. After brazing of the upper part of water box, all brazed joints are subjected to a helium leakage test oreceded by a thermal shock test. The tangential air clearance between the water boxes and bar connections within a coil group and the axial clearance relative to the inner shields, which is at ground potential, is so dimensioned that additional insulation is not required. For the spaces between the individual phases insulating caps, which enclose both the connecting sleeves and the water boxes, are connected to the stator bars. Phase Connectors:- The phase connectors interconnect the coil groups and link the beginning and ends of the winding to the bushings. They consist of thick-walled copper tubes. The stator bar ends coupled to the phase connectors are provided with connecting fittings which are joined to the cylindrical contact faces of the ring headers. The connection is by a bolted contact surface with Bellville washers on the bolts to maintain a uniform and constant contact pressure. The phase connectors are provided with micalastic insulation. In addition, a grounded other corona protection consisting of a semi conducting coating is applied over the entire length. At the beginnings and ends of the phase connectors several layers to semi-conductive end corona protection is applied in varying lengths. The phase connectors are mounted on the end winding supporting ring over support brackets. Neighboring phase connectors are separated with spacers and tied securely in position. This ensure a high short-circuit strength and differential movements between phase connectors and end windings are thus precluded.

23 Components for water cooling of stator windings:- 1. General: Two separate water cooling circuits are used for the stator winding and the phase connectors and bushings. All water connections between ungrounded parts and the distribution manifolds and water manifolds of the cooling circuits are insulated Teflon hoses. The water connections are equipped with O-rings of viton and Belleville washers to prevent loosening of the connection. The fittings are made from non-magnetic stainless steel. 2. Winding cooling circuit:- The end windings are enclosed by an annular water manifold to which all stator bars are connected through hoses. The water manifolds is mounted on the holding plates of the end winding support ring and connected to the primary water supply pipe. This permits the insulation resistance of the water filled stator winding to be measured. The water manifold is grounded during operation. For measurement of the insulation resistance, eg. during inspection, grounding is removed by opening the circuit outside the stator frame. The hoses, one side of which is connected to ground, consist of a metallic section to which the measuring potential is applied for measurement of the insulation resistance of the water-filled stator winding. The cooling water is admitted to three terminal bushings via a distribution water manifold flows through the attached phase connectors and is then passed to the distribution water manifold for water outlet via the terminal bushings on the opposite side. The parallel-connected cooling circuits are checked for uniform water flows by a flow measurement system covering all three phases.

24 Terminal Bushings:- 1. Arrangement of terminal bushing:- The beginning and ends of the three phases windings are brought out from the stator frame through terminal bushings, which provides for high-voltage insulation and seal against hydrogen leakage. The bushings are bolted to the bottom plate of the generator terminal box by the mounting flanges. The generator terminal box located beneath the stator frame at the exciter end is made from non-magnetic steel to avoid eddy-current losses and resulting temperature rises. Bushing-type generator current transformers for metering and relaying are mounted on the bushing outside the generator terminal box. The customers bus is connected to the air side connection flange of the bushings via terminal connectors. 2. Construction of Bushings:- The cylindrical bushing conductor consist of high conductivity copper with a central bores for direct primary water cooling. The insulator is wound directly over the conductor. It consist of impregnated capacitor paper with conducting fillers for equalization of the electrical direct-axis and quadrature-axis fields. The shirunk-on mounting sleeve consist of a gas tight casting of nonmagnetic steel with a mounting flange and a sleeve type extension extending over the entire height of the current transformers. The cylindrical connection ends of the terminal bushing conductors are silver plated and designed to accommodate bolted two part cast terminal connectors. Connection to the beginning and each phase inside the terminal box and to the external bus in by means of flexible connectors. To maintain a uniform and constant contact pressure, Belleville washers are used for all bolted connections.

25 Covers with brazed sockets for connection to the water supply are flanged to the ends of terminal bushing conductors. Rotor Shaft:- The high mechanical stresses resulting from the centrifugal forces and shortcircuit torques call for a high quality heat-treated steel. Therefore, the rotor shaft is forged from a vacuum cast steel ingot. Comprehensive tests ensure adherence to the specified mechanical and magnetic properties as well as a homogeneous forging. The rotor shaft consists of an electrically active portion, the so called rotor body, and the two shaft journals. Integrally forged flange couplings to connect the rotor to the turbine and exciter are located out board of the bearings. Approximately two-thirds of the rotor body circumference is provided with longitudinal slots which hold the field winding slot pitch is selected so that the two solid poles are displaced by 180. Due to the non-uniform slot distribution on the circumference, different moments of inertia are obtained in the main axis of the rotor. This in turn causes oscillating shaft deflections at twice the system frequency. To reduce these vibrations the deflections in the direction of the pole axis and neutral axis are compensated by transverse slotting of the pole. The solid pole are also provided with additional longitudinal slots to hold the copper bars of the damper winding. The rotor wedges act as a damper winding in the area of winding slot. Cooling of Rotor Winding:- Each turn is subdivided into eight parallel cooling zones. One cooling zone includes the slots from the center to the end of the rotor body, while another covers half the end winding.

26 The cooling gas for the slot portion is admitted into the hollow conductors through milled openings directly before the end of the rotor body and flows through the hollow conductor to the center of the rotor body. The hot gas is then discharged into the air gap between the rotor body and stator core through radial openings in the conductors and rotor slot wedges. The cooling gas passages are arranged at different levels in the conductor assembly so that each hollow conductor has its own cooling gas outlet. The cooling gas for end windings is admitted into the hollow conductor at the end of rotor body. It flows through the conductors approximate upto the pole center for being directed into a collecting compartment and is then discharged into the air gap via slots. At the end winding, one hollow conductor passage of each bar is completely closed by a brazed copper filler section. The enlargement of the conductor cross-section results in both a reduction of losses and increased conductor rigidity. Rotor Winding:- Construction:- The field winding consist of several coils inserted into the longitudinal slots of the rotor body. The coils are wound around the poles so that one north pole and one south magnetic pole are obtained. The hollow conductors have a trapezoidal cross-section and are provided with two cooling ducts of approximately semi-circular cross-section. All conductors have identical copper and cooling ducts cross-section. The individual conductors are bent to obtain half turns. After insertion into the rotor slots, there turns are combined to form full turns, the series connected turns of one slot constituting one coil. The individual coil of the rotor winding are electrically series connected.

27 Conductor Material:- The conductors are made of copper with a silver content of approximately 0.1%. As compared to electrolytic copper, silver-alloyed copper features high strength properties at higher temperatures so that coil deformations due to thermal stresses are eliminated. Insulation:- The insulation between the individual turns is made of layers of glass fiber laminate. The coils are insulated from the rotor body with L-shaped strips of glass fiber laminate with Nomex filler. To obtain the required creepage paths between the coil and the frame thick top strips of glass fiber laminate are inserted below the slot wedges. Loactions of parts in the Rotor Winding: Rotor Slot Wedges:- To protect the winding against the effects of the centrifugal force, the winding is secured in the slots with wedges. The slot wedges are made from a copper-nickel-silicon alloy featuring high strength and good electrical conductivity, and are used as damper winding bars. The slot wedges extend below the shrink seats of the retaining rings. The rings act as short-circuit rings to induced currents in the damper windings. End Winding Bracing:- The spaces between the individual coils in the end winding are filled with insulating members which prevent coil movement. Rotor Retaining Ring:- The rotor retaining rings contain the centrifugal forces due to the end winding. One end of each ring is shrunk on the rotor body, while the other end of

28 the ring overhangs the end windings without contacting the shaft. This ensures an unobstructed shaft deflection at the end windings. The shrunk on end ring at the free end of the retaining ring serves to reinforce the retaining ring and secures the end winding in the axial direction at the same time. A snap ring is provided for additional protection against axial displacement of the retaining ring. To reduce the stray losses and retain strength, the rings are made of nonmagnetic cold worked material. Comprehensive tests, such as ultrasonic examination and liquid penetrate examination, ensure adherence to the specified mechanical properties. The retaining ring shrink-fit areas act a short-circuit rings to induced currents in the damper system. To ensure low contact resistance the shrink seats of the retaining rings are coated with nickel, aluminum and sliver by a three step flame spraying process. Field connections:- The field connections provides the electrical connection between the rotor winding and the exciter and consist of 1. Field current lead at end winding. 2. Radial bolts. 3. Field current lead in shaft bore. Field current lead at End Winding:- The field current lead at the end winding consist of hollow rectangular conductors. The hollow conductors are inserted into shaft slots and insulated. The are secured against the effect of centrifugal force by steel wedges. The end of each field current lead is brazed to the rotor winding and the other end is screwed to a

29 radial bolt. Cooling hydrogen is admitted into the hollow conductors via radial bolts. The hot gas is discharged into the air gap discharged into the air gap together with the gas used to cool the end winding. Radial Bolts:- The field current leads located in the shaft bore are connected to the conductors inserted in the shaft slots through radial bolts which are secured in position with slot wedges. Contact pressure is maintained with a tension bolt and an expanding cone in each radial bolt. Contact pressure increases due to centrifugal forces during operation. All contact surface are silver-plated to attain a low contact resistance. The radial bolt is made from forged electrolytic copper. The seal between air and hydrogen spaces is located close to the radial bolt. This seal consists of an insulating ring which is pressed between the shaft and the radial bolt with a threaded ring. 3. Field current lead in shaft bore:- The leads are run in the axial direction from the radial bolt to the exciter coupling. They consist of two semicircular conductors insulated from each other and from the shaft by a tube. The field current leads are connected to the exciter leads at the coupling with Multi Kontakt plug in contacts, which allow for unobstructed thermal expansion of the field current leads. Rotor Fan:- The generator cooling gas is circulated by one axial-flow fan located on the turbine-end shaft journal. To augment the cooling of the rotor winding, the pressure established by the fan works in conjunction with the gas expelled from the discharge parts along the rotor. The moving blades of the fan are inserted into T-shaped grooves in the fan hubs. The fan hubs are shrink-fitted to the shaft journal spider.

30 Generator Bearings:- The rotor shaft is supported in sleeve bearings having forced-oil lubrication. The bearings are located in the stator end shields. The oil required for bearing lubrication and cooling is obtained from the turbine oil system and supplied to the lubricating gap via pipes permanently installed inside the lower half of the stator end shield and via grooves in the bearing sleeves. The lower bearing sleeve rests on the bearing saddle via three brackets with spherical support sets for self-alignment of the bearing. The bearing saddle is insulated from the stator end shield and the bearing bracket are insulated from the bearing sleeve to prevent the flow of shaft currents and to provide for double insulation of the generator bearing from ground. A radial locator serves to locate the bearing in the vertical direction and is bolted to the upper half of the stator end shield. The locator is adjusted to maintain the required clearance between the bearing sleeve and the insulation of the radial locator. A tangential locator is provided at the bearing sleeve joint to prevent the bearing from turning in the saddle. The tangential locator is supported on the bearing saddle over a piece of insulating material. The inner surface of the cast bearing sleeve body is provided with spiral dovetail grooves, which firmly hold the Babbitt liner to the bearing sleeve body. The lower bearing sleeve has a groove to admit the bearing oil to the bearing surface the upper sleeve has a wide overflow groove through which the oil is distributed over the shaft journal and fed to the lubricating gap. The oil is drained laterally from the lubricating gap, caught by baffles and returned to the turbine oil tank. All generator bearings are provided with a hydraulic shaft lift oil system to reduce bearing friction during start up. High pressure oil is forced between the bearing surface and the shaft journal, lifting the rotor shaft to allow the formation of the lubricating oil film.

31 The bearing temperature is monitored with one double element thermocouple located approximately in the plane of maximum oil film pressure. Shaft Seal:- The rotor shaft ends are brought out of the gastight enclosure through double flow shaft seals. With this type of shaft seal, the escape of hydrogen between the rotating shaft and the housing is prevented by maintaining a continuous film of oil between the shaft and a non-rooting floating seal ring. To accomplish this, seal oil from two separate circuits i.e., the air side and hydrogen side seal oil circuits, is fed to the seal ring at a pressure slightly higher than the hydrogen pressure. In addition, higher pressure air side oil is supplied to the shaft seal for thrust load compensation of the seal ring. The double flow shaft seal is characterized by its short axial length, its independence from the respective axial and radial position of the shaft, and low hydrogen losses due to absorption by the seal oil. The two halves of the babbitted seal ring float on the shaft journal with a small clearance and are guided in the axial direction by a seal ring carrier resistant to distortion and bending. The seal ring is relatively free to move in the radial direction, but is restrained from rotating by use of a pin. The seal ring carrier, bolted to the end shield is insulated to prevent the flow of shaft current. The oil is supplied to the shaft seal at three different pressures over pipes and the mounting flanges of the seal ring carrier at the end shield. The air side and the hydrogen side seal oil is admitted into the air side and hydrogen side annular grooves, respectively, of the seal ring via passages in the seal ring carrier and seal ring. A continuous film of oil is maintained between the shaft and the seal ring clearance between the shaft and seal ring is such that friction losses are minimized and a oil film of sufficient thickness is maintained without an unnecessarily large oil flow. Temperature rise of the seal oil is therefore small which contributes to reliable

32 sealing. The Babbitt lining of the seal ring ensures high reliability even in the event of boundary friction. The air side seal oil pump delivers the oil at a pressure maintained at 71.4 bar above the generator hydrogen gas pressure at the shaft seal by means of differential pressure value ("A" value). On the hydrogen side, the hydrogen saturated seal oil is circulated in a closed circuit. A pressure equalizing value maintains the oil pressure on the hydrogen side slightly below that on the air side, thus keeping the interchange of oil between the air and hydrogen sides to a very small value. Air side seal oil for ring relief is fed to the annular groove in the air side seal ring carrier and forced between the seal ring and seal ring carrier. In this way the oil and gas pressure acting on seal ring are balanced, and the friction between the seal ring and seal ring carrier is reduced. The seal ring is thus free to adjust its radial position, which is important during the starting and shut-down period. The seal ring will adjust its position according to the shaft position as dictated by the oil film thickness and the vibratory condition. The seal ring need not follow the axial displacement of the generator shaft, which is primarily caused by turbine expansion. The design permits the shaft to slide through the seal ring without impairing the sealing effect. Hydrogen Cooler:- The hydrogen cooler is a shell and tube type heat exchanger which cools the hydrogen gas in the generator. The heat removed from the hydrogen is dissipated through the cooling water. The cooling water flows through the tubes while the hydrogen is passed around the finned tubes. The cooler consists of individual sections for vertical mountings. This arrangement permits the coolers to be mounted without an increase in the overall generator axial length or cross-sectional area of the stator frame. The hydrogen flows through the coolers in the horizontal direction. The cold cooling water flows from the bottom to the top end of the cooler on the cold gas